Three-Dimensional Apertured Film For Transmitting Dynamically-Deposited And Statically-Retained Fluids

ABSTRACT

A three-dimensional film for use as a transfer layer in an absorbent article has a continuous surface and a discontinuous surface disposed generally parallel to and spaced from said continuous surface; both the continuous surface and the discontinuous surface have large scale apertures defined by sidewalls originating on the surface and extending outwardly therefrom and sized to permit acquisition of fluids by gravity, and optionally each surface also includes small scale apertures sized to acquire fluids by capillary action.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/462,565, filed Aug. 4, 2009, which is a continuation-in-part of U.S.application Ser. No. 12/316,323, filed Jan. 29, 2009, now U.S. Pat. No.8,415,524, which in turn is a continuation of U.S. application Ser. No.11/559,601, filed Nov. 14, 2006, now U.S. Pat. No. 7,518,032, thedisclosures of which are incorporated herein by references in itsentirety.

BACKGROUND OF INVENTION

The present invention relates, generally, to a three-dimensionalaperture film for use as a transfer layer in an absorbent article.

Absorbent articles for absorbing body fluids are well known. Thesearticles typically comprise an absorbent core covered by a topsheet,which is positioned adjacent to, and, in use, may contact the user'sskin. The topsheet for use in an absorbent article is typically anaperture film, nonwoven, or laminated combinations thereof. Examples ofsuch absorbent articles include diapers, incontinent articles, andsanitary napkins.

One problem associated with absorbent articles is maintaining thedryness of the wearer-facing surface of the topsheet. Generally, whenthe wearer-facing surface is kept dry, the absorbent article is morecomfortable. To maintain a dry wearer-facing surface, the absorbentarticle should be able to eliminate both dynamically-deposited andstatically-retained fluids from the topsheet and transmit them to theabsorbent core. Dynamically-deposited fluids are generally voluminousfluids expelled by the user, while statically-retained fluids areresidual fluids held in or on the topsheet by surface tension. Inaddition, the articles need to be able to keep fluids transmitted to thecore from migrating back to the wearer-facing side of the article—aphenomenon known as rewet.

Dynamically deposited fluids must be rapidly transmitted to theabsorbent core to the minimize wearer discomfort and to prevent thelateral run off of fluids leading to leakage and garment soiling. Thisrapid transmission of dynamically-deposited fluids by the topsheet tothe absorbent core is at a rate greater than the absorbent rate of thecore. This feature is particularly true with cores that containsignificant amounts of superabsorbent polymers. Such polymers have arate of intake that is inversely proportional to their fluid holdingpower. Thus, while such polymers have the ability to hold significantamounts of fluids, it is often the case that they take time to fullyabsorb that fluid. This causes pooling of unabsorbed fluid on the coresurface and leads to higher levels of statically-retained fluid over alarger area of the topsheet.

The use of a transfer layer is intended to address these issues. Thetransfer layer is interposed between the topsheet and the core andserves several main functions. First, the transfer layer provides a voidspace for fluids to accumulate away from the wearer until they can beabsorbed by the core. Secondly, the transfer layer provides a way tolaterally disperse the fluids from a saturated area of the core to aless saturated area. Finally, transfer layers made of formed films (asopposed to fibrous nonwoven webs) offer an additional physical barrierbetween the core and the topsheet and thus help reduce rewet.

SUMMARY OF THE INVENTION

In one embodiment, the disclosure provides a three-dimensional aperturedfilm for use as a transfer layer in an absorbent article. The film hasone set of apertures which originate from a continuous surface of thefilm and a second set of apertures that originate from a discontinuoussurface of the film. The apertures in the discontinuous surface compriseat least one large scale aperture, which is capable of transmittingdynamically-deposited fluids through the film by gravity. Thediscontinuous surface can optionally also include small scale apertures,which are capable of transmitting statically-retained fluids through thefilm by capillary action. The apertures in the continuous surface cancomprise large scale apertures, small scale apertures, or combinationsthereof.

In another embodiment, the disclosure provides an absorbent articlehaving a topsheet, an absorbent core, and a transfer layer locatedbetween the topsheet and the absorbent core, wherein the acquisitiondistribution layer comprises a three-dimensional apertured film havingone set of apertures which originate from a continuous surface of thefilm and a second set of apertures that originate from a discontinuoussurface of the film. The apertures in the discontinuous surface compriseat least one large scale aperture, which is capable of transmittingdynamically-deposited fluids through the film by gravity. Thediscontinuous surface can optionally also include small scale apertures,which are capable of transmitting statically-retained fluids through thefilm by capillary action. The apertures in the continuous surface cancomprise large scale apertures, small scale apertures, or combinationsthereof.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a cross-sectional view of a schematic of an absorbentarticle in accordance with an embodiment of the disclosure.

FIG. 2 shows a cross-sectioned view of a three-dimensional aperturedfilm in accordance with an embodiment.

FIG. 3 shows a cross-sectioned view of a three-dimensional aperturedfilm in accordance with an embodiment.

FIG. 4 shows a cross-sectioned view of a three-dimensional aperturedfilm in accordance with an embodiment.

DETAILED DESCRIPTION

Referring to FIG. 1, a simplified representation of a typical absorbentarticle 10 is shown. The absorbent article 10 basically comprisestopsheet 12, acquisition distribution layer 15, absorbent core 16, and abacksheet 14. Other layers may be included in this general construction.Examples of absorbent articles include diapers, incontinent articles,sanitary napkins, and similar articles. It should be understood,however, that FIG. 1 is shown for purposes of example only, and shouldnot be construed to limit the particular type or configuration ofabsorbent article.

As shown in FIG. 1, the absorbent article 10 has two surfaces, awearer-facing surface or wearer surface 18 and a garment-facing surfaceor garment surface 20. The wearer surface 18 is intended to be wornadjacent to the body of the wearer. The garment surface 20 of theabsorbent article 10 is on the opposite side and is intended to beplaced adjacent to the wearer's undergarments or clothing when theabsorbent article 10 is worn.

As can be seen in FIG. 1, when used as a transfer layer for an absorbentarticle, the three-dimensional film 15 is located beneath the topsheet12 and adjacent to the top or wearer-facing side 17 of the absorbentcore 16. In a preferred embodiment, the topsheet comprises any nonwovenweb of individual fibers or threads which are interlaid, but not in anyregular, repeating manner. Any nonwoven web commonly known in that artas suitable for topsheet applications can be used. Nonwoven webs havebeen, in the past, formed by a variety of processes such as, forexample, meltblowing processes, spunbonding process, and bonded cardedweb processes. In lieu of or in addition to a nonwoven web, the topsheet12 may comprise a three-dimensional film, as is known in the art.

Referring now to FIG. 2, the three-dimensional film 15 comprises acontinuous surface 22 with a plurality of drains 24 therein. The term“continuous surface” means that any point on the surface 22 can bereached from any other point on the surface 22 without breaking contactwith the surface. The drains 24 are defined by sidewalls 26 thatoriginate in surface 22 and extend downwardly from the surface 22 in az-direction, terminating in an aperture 28 at the distal end of thesidewalls 26. The z-direction is defined as generally transverse to theplane of the film and is indicated by arrow “Z” in FIGS. 2-4.

The film 15 further comprises protrusions 30 having a top surface 32.The top surfaces 32 collectively comprise a discontinuous surface thatis spaced from and generally parallel to the continuous surface 22. Theterm “discontinuous surface” means that any point on the surface 32cannot be reached from any other point on the surface 32 withoutbreaking contact with the surface. The top surface of any one protrusionis a continuous surface, but the surfaces 32 of individual protrusions30 collectively form a discontinuous surface in the film.

A plurality of drains 34 are defined by sidewalls 36 that originate insurface 32 and extend downwardly from the surface 32, terminating in anaperture 38 at the distal end of the sidewalls 36. The drains 34 andsidewalls 36 are thus oriented toward the continuous surface 22 and inthe same direction as the apertures 24 and sidewalls 26, but spaced in adifferent plane. In addition to drains 34, the discontinuous surface 32may contain capillaries, such as capillary 33. The capillary 33 has thesame basic construction as the drains 34 and is defined by sidewalls 35that originate in the discontinuous surface 32 and extend outwardlytherefrom. An aperture 37 is located at the distal end of the sidewalls35, thus providing fluid communication through the capillary 33.

With reference to FIG. 3, the three-dimensional film 115 comprises acontinuous surface 22 with a plurality of buckets 40 therein. In thisembodiment, the buckets 40 are also defined by sidewalls 42 thatoriginate in the continuous surface 22 and extend downwardly in thez-direction. Buckets 40 further comprise a bottom wall 44 orientedgenerally parallel to continuous surface 22. At least one of thesidewalls 42 contains an aperture 46 therein. The bottom wall (alsoreferred to as bottom surface) 44 is substantially unapertured. Byproviding an aperture in the sidewall and leaving the bottom surfacesubstantially intact, the transfer layer 115 can provide fluidmanagement and also provides nearly complete visual occlusion of theabsorbent core. The near complete visual occlusion enables an absorbentarticle with improved masking properties to hide a soiled absorbentcore, which is a benefit and desirable property to consumers.

It will be understood that the placement of the aperture 46 is notexact. Nor is the line of demarcation between the bottom surface 44 andthe sidewall 42 always well defined. Accordingly, in practice it may bethat a portion of bottom surface 44 is apertured, even if most of theaperture 46 is located in the sidewall. For this reason, when we statethat the bottom surface 44 is substantially unapertured, we mean that nomore than 10% or 12%, preferably no more than 5%, of the surface area ofthe bottom surface 44 is occupied by the aperture. Similarly, when westate that the aperture 46 is in the sidewall 42, we do not mean toimply that the 100% of the open area is in the sidewall portion.

The embodiments having apertures 46 in the sidewalls 42 allows forbetter control and flexibility of the z-direction dimension of the film.In particular, unlike the typical apertured three-dimensional formedfilm, the z-direction dimension of the transfer layer is determined bythe depth (i.e., thickness) of the forming screen and not by thediameter of the opening in the screen corresponding to the diameter ofthe protuberance.

In addition, as seen in FIG. 3, the film 115 contains capillaries 48that are defined by sidewalls 47 that originate in the continuoussurface 22 and extend downwardly therefrom in the z-direction andterminate in an aperture 49 at the distal end of the sidewall 47. Filmscontaining sidewall apertures and capillaries are disclosed in theaforementioned co pending and commonly assigned U.S. application Ser.No. 12/291,427, filed Nov. 10, 2008, the disclosure of which isincorporated herein by reference.

The film 115 of FIG. 3 further comprises protrusions 30 having a topsurface 32. As in FIG. 2, the top surfaces 32 collectively comprise adiscontinuous surface that is spaced from and generally parallel to thecontinuous surface 22. A plurality of drains 34 are defined by sidewalls36 that originate in surface 32 and extend downwardly from the surface32, terminating in an aperture 38 at the distal end of the sidewalls 36.The drains 34 and sidewalls 36 are thus oriented toward the continuoussurface 22 and in the same direction as the drains 24 and sidewalls 26,but spaced in a different plane. As in previous embodiments, thediscontinuous surface may also include capillaries, such as capillary33.

In reference to FIG. 4, the film 215 comprises a continuous surface 22with a plurality of drains 24 therein. The drains 24 are defined bysidewalls 26 that originate in surface 22 and extend downwardly from thesurface 22 in a z-direction, terminating in an aperture 28 at the distalend of the sidewalls 26.

The film 215 of FIG. 4 further comprises protrusions 30 having a topsurface 32. The top surfaces 32 collectively comprise a discontinuoussurface that is spaced from and generally parallel to the continuoussurface 22. A plurality of drains 34 are defined by sidewalls 36 thatoriginate in surface 32 and extend downwardly from the surface 32,terminating in an aperture 38 at the distal end of the sidewalls 36. Thedrains 34 and sidewalls 36 are thus oriented toward the continuoussurface 22 and in the same direction as the apertures 24 and sidewalls26, but spaced in a different plane. As in previous embodiments, thediscontinuous surface may also include capillaries, such as capillary33.

As also seen in FIG. 4, the film 215 further comprises at least onebasin 50 defined by sidewalls 52 that originate in the continuoussurface 22 and extend downwardly in the z-direction and bottom wall 54oriented substantially parallel to the continuous surface 22. The bottomwall 54 contains at least one aperture 56 defined by sidewalls 58 thatoriginate at the bottom wall 54 and extend downwardly. An aperture 60 islocated at the distal end of sidewalls 58, permitting fluids collectedin basin 50 to pass through the film 215 in the z-direction.

When viewed from above, the shape of the apertures, whether they aredrains, capillaries, basins or buckets, may be circular, oval,elliptical, polygonal, or other desired shape. Moreover, the aperturesmay be arranged in any desired pattern or array and in any desireddensity or mesh count (i.e., the number of apertures per unit length). Amesh count of 2-25 drains, buckets or basins per linear inch, morepreferably 8-20 apertures per linear inch is generally suited fortransfer layers in absorbent articles.

In a preferred embodiment, the films transmits dynamically-depositedfluids at a controlled rate using drains in conjunction with basinsand/or buckets that are able to collect and temporarily hold fluidbefore transmitting such fluid to the core. This gives the absorbentcore more time to absorb the fluid.

Drains 24, buckets 40 and basins 50 (collectively referred to as “largescale apertures”) have diameters which are large enough to allow insultfluids to be acquired through the three-dimensional film by gravity orby application pressure, preferably as rapidly as the fluids aredelivered. The capillaries (also called “small scale apertures”) 33, 48are sized such that the capillaries exhibit capillary action and thusare able to transmit fluid in contact with the discontinuous surface 32or the continuous surface 22.

The protrusions 30 extend upward from the continuous surface 22. In apreferred embodiment, the discontinuous surface 32 of the protrusions 30will come in contact with the lower surface of the topsheet 12 or extendinto the topsheet 12. The number and arrangement of drains 34 andcapillaries 33 in the discontinuous surface 32 of the protrusions 30 isnot particularly important to the invention and any suitablearrangement, pattern or mesh count may be employed as desired, so longas at least one drain 34 is present. In a preferred embodiment, theprotrusions 30 contain 1 to 10 drains, and more preferably 3 to 5drains. Optionally, each protrusion 30 may contain 1-10 capillaries.

The z-direction dimension or loft of the films may be 400 to 1700microns, depending on the embodiment. The z-direction distance from thecontinuous surface 22 of the film to the discontinuous surface 32 of theprotrusions 30 can be 50 to 300 microns, more preferably 100 to 250microns, and most preferably 200 microns. Although FIGS. 2 and 4illustrate the discontinuous surface 32 of protrusions 30 as being in acommon plane, this is not an essential feature. Accordingly, eachprotrusion 30 may be higher or lower than any other protrusion 30 ifdesired.

Preferably, the drains and capillaries are tapered whereby their largestdiameter is at the opening on the surface 22 or 32. The taperingdecreases the likelihood that fluid will be transmitted through the filmfrom the core to the topsheet. The drains, buckets and basins need notbe cylindrical in shape to function in their intended manner as long asthey are large enough to allow dynamically-deposited fluids to beacquired through the three-dimensional film rapidly. Accordingly, thesefilm structures must be sized and have the proper surface chemistry sothat they do not present a barrier for dynamically-deposited fluids. Ithas been found that diameters greater than 400 microns, more preferablygreater than 650 microns, do not present a barrier to fluid flow.

The upper limit of the diameter is determined primarily on aesthetic andon the basis of rewet considerations. That is, larger diametersapertures in the film tends to make the film appear very stiff andharsh, which creates a negative impression with the consumer. Likewise,for larger diameters also create a greater likelihood that fluid can betransmitted from the absorbent core (e.g., upon compression) through thefilm to the topsheet. In a preferred embodiment, the large scaleapertures, such as drains, buckets or basins have diameters preferablyno greater than 1200 microns, and more preferably no greater than 1000microns.

If the apertures, be they drains, basins, buckets or capillaries, do nothave a “true” diameter (e.g., they have an oval opening), they should besized to ensure that they have an equivalent hydraulic diameter (EHD)equal to the respective diameters discussed herein. As used herein, theterm equivalent hydraulic diameter is defined by the following equation:EHD=4A/P where A is the area of the irregular aperture and P is theperimeter of the irregular aperture. The equivalent hydraulic diameteris the diameter of a circular aperture having fluid flow characteristicssimilar to the irregular aperture for which the calculation is beingdone. See U.S. Pat. No. 4,324,246 which is incorporated herein byreference. Therefore, the term “diameter” as used herein refers toeither the apparent diameter or the EHD.

The apertures are preferably irregularly shaped openings randomlydistributed in the topsheet. The apertures may be of equal or ofdifferent sizes provided that less than about 25 percent of theapertures have a small equivalent hydraulic diameter (EHD).

The capillaries have a smaller diameter such that they do not functionappreciably in dynamic situations to transmit significant quantities ofrapidly discharged fluid directly to the underlying absorbent core.Rather, the capillaries, if properly sized and positioned, can removestatic fluid through the film. The capillaries need to be cylindrical tofunction in the intended manner. They can be either regular or irregularin shape. The capillaries, however, must be sized and the proper surfacechemistry so that they exhibit capillary action. It has been found thatcapillaries with diameter of less than 375 microns, more preferably lessthan 250 microns will exhibit capillary action.

In a preferred embodiment, the ratio of the diameter of the smallest ofthe large aperture structures (i.e., drains, basins and buckets) to thatof the diameter of the largest capillary is preferably at least about 2,and more preferably at least about 4. These ratios tend to ensure thatthe three-dimensional film will effectively transmitdynamically-deposited fluids by gravity and remove static fluid from thetopsheet by capillary action.

Preferably, the three-dimensional films are perforated thermoplasticfilms which have a percent run off of less than about 10 percent andwhich have an increased liquid flow rate through the tapered drains. Anythermoplastic material which may be formed into flexible film or sheetsmay be used in the production of the novel film of the presentinvention. Percent run off is a well known test for absorbent articlesthat quantifies the ability of the article, or its component parts toacquire liquid. This is measured by a fluid run-off test wherein thetest specimen is held at an angle to the horizontal and fluid is appliedto the specimen and the amount of fluids that run off the specimen arecompared to the amount of fluid that is acquired.

In use, the cover fabric may be wet with baby oil, lotions, etc., fromthe babies' skin, so the test is also run on a diaper section that hashad 1 gram of baby oil (Johnson's Baby Oil) spread evenly over itssurface by transfer from a plastic sheet. Stip tensile strength andelongation at break are measured on an Instron Tester at 70° F. and 65percent relative humidity using 1.0-inch wide samples with a 2-inchdistance between jaws and elongating at 50 percent per minute. Theresults are given in pounds/inches (lb.//in.) for machine direction (MD)and cross direction (XD) as MD/XD.

Exemplary thermoplastic materials include polyesters, polyamides, vinylpolymers and copolymers, e.g., vinyl acetates, vinyl alcohols, vinylchlorides; poly methacrylates, poly lactic acid, and polyolefins, e.g.,polyethylene, polypropylene, and copolymers or blends thereof which maybe formed into flexible film or sheet. Particularly preferred perforatedfilms are polyethylene and polypropylene. One suitable material is apolyethylene film having a thickness of from about 20 microns to about50 microns. Sheets or film made from such materials may containadditives known in the art to achieve the desired physicalcharacteristics.

When using a hydrophobic thermoplastic material such as a polyolefinresin to form the three-dimensional film, the film can be treated tomake the film act more hydrophilic. In one embodiment, a migrating orblooming surfactant can be incorporated into the resin mixture prior toextruding the blend to form the film. The migrating surfactant bringsmore polar moieties to the film surface but they technically don't makethe film more polar and therefore wettable. Free surfactants such asthose that bloom from a film accomplish wetting not by increasing thesurface energy of the film but rather dissolve into the liquid and lowerits surface tension to cause wetting. In another embodiment, the filmmay be exposed to corona treatment after it is formed. Corona treatmentintroduces ionic species onto the film surface that are bound (at leasttemporarily) to the surface and they do increase the surface energy ofthe film. Corona treatment also introduces energy into the film thatenhances surfactant migration to the film surface. Such methods areknown in the art and are taught, for example by U.S. Pat. Nos. 4,535,020and 4,456,570, which are incorporated herein by reference. In yetanother embodiment, the films may be multilayer films containing a thin,hydrophilic “skin” layer on the wearer topsheet facing surface and thehydrophobic resin blend at the layer furthest from the topsheet. Thehydrophilic skin layer may contain a non-migrating surfactant or may becomprised of hydrophilic polymers.

As used herein, the term “hydrophilic” is used to refer to surfaces thatare wettable by aqueous fluids (e.g., aqueous body fluids) depositedthereon. Hydrophilicity and wettability are typically defined in termsof contact angle and the surface tension of the fluids and solidsurfaces involved. A surface is said to be wetted by an aqueous fluid(hydrophilic) when the fluid tends to spread spontaneously across thesurface. Conversely, a surface is considered to be “hydrophobic” if theaqueous fluid does not tend to spread spontaneously across the surface.

The three-dimensional apertured films can be made by a direct meltvacuum formed film (VFF) process. In the case of a direct melt VFFprocess, a molten web is extruded onto a forming area of a formingscreen. A pressure differential applied across the forming screen causesthe molten web to conform to the three-dimensional shape of the formingscreen to form cells that ultimately rupture at their tips to becomeapertures. Alternatively, the web may be reheated and partially meltedwhile the web is over the forming area of the forming screen as taughtin U.S. Pat. No. 4,151,240. A melted polymer is desirable to formthree-dimensional apertures since a melted polymer is more easily pulledinto the apertures in a forming screen. The three-dimensional aperturedfilms of the present invention may also be formed by a hydroformed film(HFF) process. In a HFF process, hydraulic pressure in the form of waterjets impinges upon a solid web as it crosses the forming area of aforming screen. The force of the high-pressure water causes the web toconform to the three-dimensional shape of the forming screen to formcells that ultimately rupture at their tips to become apertures.

While certain of the preferred embodiments of the present invention havebeen described and specifically exemplified above, it is not intendedthat the invention be limited to such embodiments. Various modificationsmay be made thereto without departing from the scope and spirit of thepresent invention, as set forth in the following claims.

1. A film comprising: a) a continuous surface having a plurality oflarge scale apertures originating therein, said large scale aperturesbeing defined by sidewalls originating on said continuous surface andextending outwardly therefrom; b) a discontinuous surface disposedgenerally parallel to and spaced from said continuous surface; saiddiscontinuous surface having large scale apertures therein, said largescale apertures defined by sidewalls originating on said discontinuoussurface and extending outwardly therefrom; c) wherein the large scaleapertures on the continuous surface are oriented in the same directionas the large scale apertures on the discontinuous surface.
 2. The filmof claim 1, wherein said large scale apertures are sized to allow insultfluids to be acquired through the film by gravity.
 3. The film of claim2, wherein said large scale apertures have a diameter from 400 micronsto 1000 microns.
 4. The film of claim 1, further comprising small scaleapertures on at least one of said continuous surface and saiddiscontinuous surface.
 5. The film of claim 4, wherein said small scaleapertures are sized to allow fluids to be acquired through the film bycapillary action.
 6. The film of claim 4, wherein said small scaleapertures have a diameter less than 375 microns.
 7. The film of claim 4,wherein said small scale apertures have a diameter at least 4 timessmaller than said diameter of said large scale apertures.
 8. The film ofclaim 1, wherein said large scale apertures in said continuous surfaceare drains defined by sidewalls depending from said continuous surfaceand an aperture at the distal end of the sidewalls.
 9. The film of claim1, wherein said large scale apertures in said discontinuous surface aredrains defined by sidewalls depending from said discontinuous surfaceand an aperture at the distal end of the sidewalls.
 10. The film ofclaim 1, wherein said large scale apertures in said continuous surfaceare basins, defined by sidewalls extending from said continuous surfaceand a bottom wall, said bottom wall having at least one fluid passagetherein.
 11. The film of claim 1, wherein said large scale apertures insaid continuous surface are buckets, defined by sidewalls extending fromsaid continuous surface and a bottom wall, at least one sidewall havingan aperture therein.
 12. The film of claim 1, further comprising aplurality of protrusions extending from said continuous surface, eachsaid protrusion having a top surface which collectively comprises thediscontinuous surface.
 13. The film of claim 12, wherein said topsurfaces of said protrusions are in a common plane.
 14. The film ofclaim 12, wherein said protrusions extend from 100 to 250 microns abovesaid continuous surface.
 15. An absorbent article comprising a nonwovenfibrous topsheet having an upper and lower surface; an absorbent core;and a film between said topsheet and said absorbent core; said filmcomprising: a) a continuous surface having a plurality of large scaleapertures originating therein, said large scale apertures being definedby sidewalls originating on said continuous surface and extendingoutwardly therefrom; b) a discontinuous surface disposed generallyparallel to and spaced from said continuous surface; said discontinuoussurface having large scale apertures therein, said large scale aperturesdefined by sidewalls originating on said discontinuous surface andextending outwardly therefrom; c) wherein the large scale apertures onthe continuous surface are oriented in the same direction as the largescale apertures on the discontinuous surface.
 16. The absorbent articleof claim 15, further comprising a plurality of protrusions extendingfrom said continuous surface, each said protrusion having a top surfacewhich collectively comprises the discontinuous surface.
 17. Theabsorbent article of claim 15, further comprising small scale aperturesin at least one of said continuous and discontinuous surfaces.
 18. Theabsorbent article of claim 17, wherein said small scale apertures have adiameter at least 4 times smaller than said diameter of said large scaleapertures.
 19. The absorbent article of claim 15, wherein said largescale apertures have a diameter from 400 microns to 1000 microns. 20.The absorbent article of claim 14, wherein the discontinuous surface isin contact with said topsheet.